System for producing and packing articles

ABSTRACT

A cigarette manufacturing and packing system having a connecting unit connected to a data-gathering computer; a sensor device for detecting a code identifying a work material; and a signalling device for emitting a signal relative to an instant the work material starts to be used; the connecting unit acts as a server to make available to the data-gathering computer, for a given length of time, the data received from the sensor device and the signalling device.

The present invention relates to a system and method of producing and packing tobacco products.

The present invention also relates to a unit for connecting the above system, and a method of identifying a work material.

More specifically, the present invention relates to a system—line—for producing and packing tobacco articles. The system comprises at least one manufacturing machine; at least one machine for packing the articles; and a communication network, to which a data-gathering computer is collected.

BACKGROUND OF THE INVENTION

A production system normally comprises machines of different makes, and, for each make, different types of machines produced at different times and therefore with control and automation systems of different types and technology. As a result, no one comprehensive method exists of managing production materials or acquiring and managing production material data from the machines.

Known systems of the above type have the drawbacks of failing to acquire sufficient significant data and to effectively transfer production material information to the data-gathering computer.

Another drawback of known systems is that they fail to produce production data by which to identify, relatively easily, at least one production or packing material.

SUMMARY OF THE INVENTION

It is an object of the present invention to provide a system and method of producing and packing tobacco products, a unit for connecting the system, and a method of identifying a work material in the tobacco industry, all of which are designed to at least partly eliminate the above drawbacks, while at the same time being cheap and easy to implement.

According to the present invention, there are provided a system and method of producing and packing tobacco products, a unit for connecting the system, and a method of identifying a work material, as claimed in the attached Claims.

BRIEF DESCRIPTION OF THE DRAWINGS

A non-limiting embodiment of the present invention will be described by way of example with reference to the accompanying drawings, in which:

FIG. 1 shows a schematic view in perspective of a cigarette production and packing system in accordance with the present invention;

FIG. 2 shows a block diagram of a portion of a data management system of the FIG. 1 system;

FIGS. 3 and 4 show schematic views in perspective of details of the FIG. 1 system;

FIG. 5 shows a schematic view in perspective of a detail of the FIG. 1 system.

DETAILED DESCRIPTION OF THE INVENTION

Number 1 in FIG. 1 indicates a production system for processing tobacco articles, and in particular for producing and packing cigarettes. System 1 comprises a number of automatic machines 2 arranged in series to form a cigarette manufacturing and packing line, and comprising a cigarette manufacturing machine 2 a, a filter-assembly machine 2 b, a packing machine 2 c, a cellophaning machine 2 d, and a cartoning machine 2 e. A cigarette store 3 a is interposed between filter-assembly machine 2 b and packing machine 2 c; and a store 3 b for packets of cigarettes is interposed between packing machine 2 c and cellophaning machine 2 d.

By way of a non-limiting example, the work materials used on machines 2 a, 2 b, 2 c, 2 d, 2 e comprise paper for producing the cigarettes, and paper and/or aluminium for producing the outer and/or inner packages of the packets of cigarettes, which materials are normally fed to the machines in reels; and precut sheets of paper, blanks for producing the outer package of rigid cigarette packets or cartons, and/or stamps or coupons, which materials are normally fed to the machines on pallets and/or in boxes.

In the case of a work material 8 fed to the machines in reels, each identification code C of work material 8 is applied either to the reel core or to the outer layer of the reel; and, in the case of work material supplied on pallets and/or in boxes, each identification code C of work material 8 is applied to the box.

Each code C identifies the work material in the sense of containing information relating to the supplier and/or production lot of the material.

It should be pointed out that each work material 8 is first loaded onto the machine, either by an automatic loader or manually by an operator, and is only later actually used by the machine. The moment in which the newly loaded material is actually used by the machine is normally controlled automatically by the machine itself, but, on some machines, may be controlled manually by the operator.

With particular reference to FIG. 2, system 1 comprises a data management system 4 in turn comprising a communication network 5; a data-gathering computer 6 connected to network 5; a sensor device 7 for detecting an identification code C (FIGS. 3 and 4) of a work material 8; a signalling device 9 for signalling the instant material 8 starts to be used; and a connecting unit 10 connected to devices 7 and 9 and communication network 5.

Connecting unit 10 receives and memorizes data D1 and D2 from devices 7 and 9, and substantially acts as a server to make data D1 and D2 available to computer 6.

The embodiment shown in the drawings has one connecting unit connected to all of machines 2.

In alternative embodiments, system 1 comprises the same number of connecting units 10 as machines 2, and each connecting unit 10 is associated with a respective machine 2.

A number of known computers (not shown) are optionally connected to communication network 5 to permit network access by a number of operators. In some embodiments, communication network 5 is an Ethernet type, preferably with a TCP/IP operating protocol.

In the embodiment shown, system 1 comprises two signalling devices 9: a signalling device 9 a fitted to a machine 2 to automatically signal the instant material 8 starts to be used; and a signalling device 9 b activated manually by an operator to signal the instant material 8 starts to be used.

In other embodiments, system 1 comprises no device 9 a or 9 b.

In the case of late-model automatic machines, device 9 a is connected to connecting unit 10 via an operator interface 11 (Human-Machine-Interface, HMI), which normally comprises an industrial computer, and allows the operator to interact with one or more known control units (not shown) of machine/s 2.

Operator interface 11 cyclically acquires information about the operation of corresponding machines 2 from the control unit (not shown), and organizes the information into packages, each of which is sent, in use, to and when requested by connecting unit 10. In other words, the information packages are transmitted in master/slave mode, in which connecting unit 10 is the master.

In embodiments not shown, device 9 a is connected directly to connecting unit 10, or is integrated in or connected to the control unit (not shown) which, in turn, is connected directly to connecting unit 10.

Device 9 b comprises a button 12 which is pressed by the operator to signal the instant material 8 starts to be used.

In the FIG. 3 embodiment, sensor device 7 comprises an optical reader 13, typically a television camera, for reading a two-dimensional bar code (QR code) C applied to an outer layer of a reel 14 of work material 8.

As shown in FIG. 4, in addition or alternatively, device 7 comprises an optical reader 13 for reading a code C applied to a pallet 15 of blanks 16 of work material 8.

In other embodiments not shown, optical reader 13 reads a conventional (i.e. one-dimensional) bar code C; and, in addition to or instead of optical reader 13, device 7 comprises an antenna for transmitting and/or receiving information from a transponder.

System 1 comprises a manual operating device 17, preferably comprising a button 18, by which the operator operates sensor device 7 manually.

With particular reference to FIG. 2, manual operating device 17 comprises a button 18, and is integrated with device 9 b to define a manual control device 19, in this case a two-button panel.

In the embodiment shown, sensor device 7 and operator interface 11 are connected to a communication network 20—more specifically, an Ethernet network (preferably with a TCP/IP operating protocol)—by a known switch device 21.

Connecting unit 10 comprises two Ethernet ports 22; two serial (in particular, RS422) ports 23; at least one digital input 24; and at least one digital output 25. Ethernet communication networks 5 and 20 are each connected to connecting unit 10 by a respective port 22; manual control device 19 is connected to connecting unit 10 by one of ports 23; and the unused port 23, input 24, and output 25 are indicated by dash lines in FIG. 2.

A digital input 24 is necessary to connect connecting unit 10 to automatic machines allowing no access to their production data; in which case, the control system of the machine is connected directly to digital input 24 of connecting unit 10 by a signal indicating the instant material 8 starts to be used.

In other embodiments not shown, manual control device 19 is connected to switch device 21; and/or operator interface 11 is connected to connecting unit 10 by input 24; and/or sensor device 7 is connected to connecting unit 10 by input 24; and/or communication network 5 is connected to connecting unit 10 by output 25 or one of ports 23.

In other embodiments not shown, ports 22 and 23, input 24, and output 25 differ in number and type. More specifically: connecting unit 10 does not comprise the two ports 23; and/or connecting unit 10 does not comprise input 24 and output 25; and/or connecting unit 10 only comprises one port 22, as opposed to two; and/or connecting unit 10 comprises no port 22.

Connecting unit 10 comprises an intermediate memory 26 for memorizing and making available to computer 6 data D1 relative to at least the last two codes C of material 8 read, and data D2 relative to at least two corresponding instants at which material 8 starts to be used.

Intermediate memory 26 stores and makes the above data D1 and D2 available to computer 6 for a given time, which is longer than the time taken by computer 6 to acquire data D1 and D2 from connecting unit 10.

In actual use, connecting unit 10 preferably organizes the above data D1 and D2 in packages D, each of which comprises data D1 and D2 relative, respectively, to the code C of material 8 read, and to a corresponding instant at which material 8 starts to be used.

Connecting unit 10 also comprises a bulk memory 27 (typically, a hard disk) which cyclically memorizes the data D1 and D2 of intermediate memory 26 to prevent loss of data D1 and D2 in the event computer 6 is unable, for a prolonged period, to acquire data D1 and D2 from connecting unit 10.

Connecting unit 10 also memorizes configuration information C1 comprising, for example: information relative to the enabled ports 22, 23, inputs 24, and outputs 25, and the type and presence of machine/s 2, sensor and signalling devices 7 and 9, and manual control device 19.

Connecting unit 10 also memorizes operating parameters OP comprising, for example: the addresses of sensor device 7, the first signalling device 9 over communication network 20, and connecting unit 10 over communication networks 5 and 20; and the set-ups of machine/s 2 and sensor device 7.

Connecting unit 10 also comprises an operator interface (Human-Machine-Interface, HMI) not shown, which may comprise an operator panel connected directly to connecting unit 10, or preferably an application program resident in connecting unit 10 and remote-accessible (in known manner) by any of the computers connected to one of Ethernet communication networks 5 and 20, to allow the operator to interact with connecting unit 10.

As shown in FIG. 5, system 1 also comprises an application device 28 for applying to each product P—more specifically, a container and/or article—a code E related to data D1 and D2 relative, respectively, to the work material identification code C and the instant the system starts to use the work material.

In the embodiment shown, device 28 laser-prints code E. In other embodiments, code E is ink-jet and/or pressure-printed by device 28.

Each code E preferably indicates in clear text or code the instant (in particular, the second-minute-hour-day-month-year) in which product P was produced, and the production system 1.

Alternatively, each code E may be integrated in an anti-imitation code with additional control characteristics.

A first operating mode will now be described with reference to a system in which the material is loaded onto the machine by an automatic loader, and the instant the material is actually used by the machine is controlled automatically by the machine itself.

At each operating cycle, sensor device 7, normally a television camera, automatically picks up code C identifying material 8, and emits a signal to transmit the relative data D1 to connecting unit 10; and signalling device 9 a acquires the material-change information from the control system and makes it available to the connecting unit, which acquires data D2 relative to the instant system 1 starts to use material 8 (e.g. reel 14 and/or blanks 16). At which point, connecting unit 10 memorizes and makes data D1 and D2 available to computer 6, which may decide independently the best time to acquire data D1 and D2.

A second operating mode will now be described with reference to a system in which the material is operator-loaded manually onto the machine, and the instant the material is actually used by the machine is controlled automatically by the machine itself.

At each operating cycle, the operator positions material 8 manually with code C facing sensor device 7, and presses button 12 to operate sensor device 7, which picks up code C identifying material 8, and signals the relative data D1 to connecting unit 10; and signalling device 9 a automatically signals to connecting unit 10 the data D2 relative to the instant system 1 starts to use material 8 (e.g. reel 14 and/or blanks 16). At which point, connecting unit 10 memorizes and makes data D1 and D2 available to computer 6, which may decide independently the best time to acquire data D1 and D2.

A third operating mode will now be described with reference to a system in which the material is operator-loaded manually onto the machine, and the instant the material is actually used by the machine is controlled manually by the operator.

At each operating cycle, the operator positions material 8 manually with code C facing sensor device 7, and presses button 12 to operate sensor device 7, which picks up code C identifying material 8, and signals the relative data D1 to connecting unit 10; and the operator positions material 8 ready for use by system 1. At which point, the operator presses button 18 so signalling device 9 b signals to connecting unit 10 the data D2 relative to the instant system 1 starts to use material 8 (e.g. reel 14 and/or blanks 16), and connecting unit 10 memorizes and makes data D1 and D2 available to computer 6, which may decide independently the best time to acquire data D1 and D2.

Once code E is applied to product P, the material 8 used to produce product P can be identified by comparing code E and data D1 and D2 memorized in computer 6.

More specifically, when code E indicates in clear text or in code the instant product P was produced, and the production system 1, the material 8 being used at that time on system 1 need simply be determined.

System 1 and connecting unit 10 are therefore highly versatile, and provide for effectively managing a large quantity of significant information.

In this connection, it should be pointed out that connecting unit 10 safeguards against computer 6 being unable to acquire data D1 and D2, on account of being engaged in other operations.

Also worthy of note is the fact that the present invention provides for relatively easily and cheaply identifying at least one production or packing material 8 employed. 

1) A system—line—for producing and packing tobacco articles, the system (1) comprising at least one manufacturing machine (2 a; 2 b); at least one machine (2 c; 2 d; 2 e) for packing said articles; at least one data-gathering computer (6); a first communication network (5) to which the data-gathering computer (6) is connected; and at least one sensor device (7) for detecting a code (C) identifying a work material (8), and for emitting a relative signal; the system (1) being characterized by comprising: at least a first signalling device (9 a; 9 b) for emitting a signal relative to an instant the system (1) starts using the work material (8); and a connecting unit (10) connected to the first communication network (5), to the sensor device (7), and to the signalling device (9 a; 9 b); the connecting unit (10) receiving and memorizing data (D1, D2) relative to the code (C) identifying the work material (8), and to the instant the system (1) starts using the work material (8); and the connecting unit (10) making the memorized said data (D1, D2) available to allow the data-gathering computer (6) to acquire the data (D1, D2) over the first communication network (5). 2) A system as claimed in claim 1, and comprising an application device (28) for applying a code (E), relative to said data (D1, D2), to each product (P), in particular a container and/or article. 3) A system as claimed in claim 1, wherein the connecting unit (10) comprises an intermediate memory (26) for memorizing, and making available to the data-gathering computer (6), data (D1) relative to at least the last two codes (C) of the work material (8) read, and data (D2) relative to at least two corresponding instants at which the work material (8) starts to be used. 4) A system as claimed in claim 1, wherein the connecting unit (10) comprises an intermediate memory (26) for memorizing and making said data (D1, D2) available to the data-gathering computer (6) for a given time; the given time being longer than the time taken by the data-gathering computer (6) to acquire the data (D1, D2) from the connecting unit (10). 5) A system as claimed in claim 1, wherein the connecting unit (10) organizes the data (D1, D2) into packages (D), each of which comprises data (D1) relative to a code (C) identifying the work material (8), and to a corresponding instant at which the work material (8) starts to be used. 6) A system as claimed in claim 1, wherein the connecting unit (10) comprises at least one Ethernet port (22). 7) A system as claimed in claim 6, wherein the connecting unit (10) comprises at least two Ethernet ports (22). 8) A system as claimed in claim 1, wherein the connecting unit (10) comprises at least one serial port (23), in particular an RS422 serial port. 9) A system as claimed in claim 1, wherein the connecting unit (10) comprises at least one digital input (24) and one digital output (25). 10) A system as claimed in claim 1, wherein the connecting unit (10) memorizes configuration information (C1). 11) A system as claimed in claim 10, wherein the configuration information (C1) comprises information relative to the enabled ports (22; 23; 24; 25) of the connecting unit (10). 12) A system as claimed in claim 1, wherein the connecting unit (10) memorizes operating parameters (OP) relative to the sensor device (7), the first signalling device (9 a; 9 b), and the connecting unit (10) itself. 13) A system as claimed in claim 12, and comprising a second communication network (20), to which the sensor device (7) and the first signalling device (9 a; 9 b) are connected; and the operating parameters (OP) comprise the addresses of the sensor device (7) and the first signalling device (9 a; 9 b) over the second communication network (20), and of the connecting unit (10) over the first and second communication network (5, 20). 14) A system as claimed in claim 1, and comprising a manual operating device (17) by which an operator may operate the sensor device (7) manually. 15) A system as claimed in claim 1, wherein the first signalling device (9 a) automatically emits the signal relative to the instant the system (1) starts using the work material (8). 16) A system as claimed in claim 15, and comprising a second signalling device (9 b) which may be operated by an operator to manually signal the instant the system (1) starts using the work material (8); the connecting unit (10) being connected to the second signalling device (9 b). 17) A system as claimed in claim 16, wherein the second signalling device (9 b) comprises at least one button (12). 18) A system as claimed in claim 1, and comprising a manual operating device (17) by which an operator may operate the sensor device (7) manually; the manual operating device (17) and the second signalling device (9 b) being integrated to define an interface device (19). 19) A system as claimed in claim 18, wherein the interface device (10) comprises a panel having at least two buttons (12, 18). 20) A connecting unit defined as claimed in claim 1, and comprising at least one input (22; 23; 24) to connect the sensor device (7) and the first signalling device (9 a) to the connecting unit (10); and at least one output (22; 23; 25) to connect the first communication network (5) to the connecting unit (10). 21) A method of producing and packing tobacco articles; the method comprising a read step to read a code (C) identifying a work material (8); and the method being characterized by comprising a signalling step to emit a signal relative to an instant at which the work material (8) starts to be used; a memorizing step to memorize data (D1, D2) acquired at the signalling and read steps; and an application step to apply on each product (P), container, and/or article a code (E) indicating when the product (P) was produced. 22) A method of identifying at least one work material used to produce a product (P), in particular a container and/or article, in the tobacco industry; the method comprising a read step to read a code (C) identifying a work material (8); and the method being characterized by comprising a signalling step to emit a signal relative to an instant at which the work material (8) starts to be used; a memorizing step to memorize data (D1, D2) acquired at the signalling and read steps; an application step to apply on the product (P) a code (E) indicating when the product (P) was produced; a second read step, after said read, signalling, and application steps, to read the code (E) applied to the product (P); and an analysing step to compare the read code (E) with the memorized data (D1, D2) to identify the material (8) used to produce the product (P). 